FERRARINI & BENELLI CORONA TREATIM SINT VERSION 7.0 11/03/2013& FERRARINI & BENELLI FERRARINI & BENELLI Dal 1965 tecnologie vincenti 2 4+39-0373-729272 io +39-0373-270131 #27 info@ferben.com P www.ferben.com an VIA DEL COMMERCIO 22 — 26014 ROMANENGO -— CR - ITALY & Customer Assistance Service gay tech@ferben.com FERRARINI & BENELLI uses only EC standard components. connor IGBI :FERRARINI 8 BENELLI CORONA TREATMENT INDEX ] L. Index... Use of the instruction manual . Symbols description... 2 3, 4. Guarantee o Standard references 5.1 Treatment station... S.1.1 European directives, 5.1.2. Technical stendards. 52 Generator. 52.1 European directives... 5.2.2 Technical standards, 6. Danger zones.. 61 High voltage 6.2 Harmful gases... 6.3 Moving parts. 7. Purpose of the equipment... General safety standard 0. a‘ 8.1 Open/close of pneumatic system Ofproied. a: 82 Ozone... 83 Motorization of the discharge roll. 9. Instructions for emergencies situations.. 10. General information 10.1 The purpose of the surface treatment. s . 10.2 Methods of improving the surface treatment ....e.s 16 10.3 How to obtain the Corona discharge’s effect 16 10.4 Corona’s factors and parameters ....c0..0e- ang IF 11. Generator specifications. 11.1 Supply..... 1.2 Protection 11.3 Identifying technical data 12, Generator layout... 121 Composition ...1. 12.1.1 Single-phase model GTS M... 12.1.2 Three-phases models GTS TLX and TMX. 12.2 Characteristics. 123 Interior views 123.1 Single-phase model GTS M. 123.2 Three-phase model GTS TLX. 1233 Three-phase model GTS TMX 13, Instructions for warehousing, disposal, handling.and installation .. 13.1 Warehousing ce 13.2.1 Treating uit ono IGBTFERRARINI & BENELLI CORONA TREATMENT 13.22. Generator : ae eatae 13.3 Handling Beets TTC BP 13.3.1 Treatment station va... Sead ee 29 133.2 Generator. % ca aac) 13.4 Installation. .cocuno oe 29 13.41 Treatment station acts s 29 1342 Generator. cna eae 31 1421 Mmodeh ncn : 32 13422 GTS TLX and GTS TMX model : 33 1343 Ozone suction an. sf 34 13.431 Examples of ideal evacuation... fi 35 14, Installation verification ... 37 15, General instructions .. 38 15.1 Generator start-up procedure. 38 15.2 Description of generator control pane 40 15.2.1 Pushbutton panel... se AL 1521.1 Keys. 41 152.12 Pilot lamp lights. 2 16, Control card functioning principle ......mmsnmne pee eieae 16.1 Card 9701 - FRNT. et 4 16.2 Card 0301 - 1/02. 44 16.3 Card 9703 ~ DRIVER or 9703B ~ DRIVER BST roo 4d 16.4 Card 0302- ALDRY or 0901-ADM ervvcvosesnensetinnnnnnnnnnnnnin A 17, Standard functions. i 145 17.1 Power control 45 17.2 Soft Start. 45 17.3. Manual power adjustment . ee 45 I74 Sern of tl width electrodes ndschares poston ca 45 ITS Sound alarm management....ssininsnninnnnnrnsnnennsnnssnsee 4 17.6 Discharge rolls speed... AT 47 17.7 Control parameter ...c00n pate . 178 Watch / Calendar .osreseeseniin 47 17.9. Historian of events.. 48 17.10 Discharge density...» on 50 17.11 Minimum STOP Speed. ST 18, Optional functiors... 18.1 Power setting of the Discharge Density... oS? 18.2 AUtOS{Ponernnenennenesieene : mer53 183 RP.V.: Adjustment of Power in function of peed ie .. 5d 18.4 Remote control i mio 184.1 System with analogical and digital signals for PLC 35 18.4.2 System with satellite keyboard Be 35 1842.1 Composition of remote system . 35 1842.2 Feeding remote system... S 35 18.423 Working. : are 18,5. Skip treatment 56 18,6 Wetstart 57 18.7 Manage of two stations. : * 59 18.8 Rapid reel change... er : 59 60 19. Stations....... connor IGBr iFERRARINI & BENELLI CORONA TREATMENT 19.1 CARTONPLAST.... 61 19.1.1 AIR-GAP adjustment 3 192 BIKAPPA ROTARY... oF 19.2.1 AIR-GAP adjustment... . 68 19.2.2 Disassembly 7F6 or SF6 electrode 65 1923 Diss and resembly the discharge als. Pee 66 1923.1 Upperroll (Rt) . ae 1923.2 Lower roll (R2) 19.3 BIKAPP4.... 19.3.1 AIR-GAP adjustment 19.3.2 Disassembly 7F6 electrode. 1933 Disassembly 9F4 electrode 193.4 Maintenance 9F4 electrode... 19.3.4.1 Disassembling — cleaning - g¥ea8iNg..ssvssse 70 193.42 _Reassembly ofthe electrode ; 70 19.3.5 Disassembly and reassembly the discharge FOIIS.esnn il 19.3.5.1 Upper roll (R1) et 19.3.5.2 Lower roll (R2) 19.4 BIKAPPA FOGLIA 19.4.1 AIR-GAP adjustment 19.4.2 Disassembly 9F4 electrode 19.4.3 Maintenance 9F4 electrode 19.43.1 Disassembling ~ cleaning - greasing 4 19.4.3. Reassembly of the electrode 4 19.4.4 Disassembly and reassembly of the discharge rolls. 74 19.4.5 Discharge roll adjustment i 75 19.5 BIKAPPA SIMPLEX... 76 19.5.1 AIR-GAP adjustment 76 19.5.2 Disassembly 7F6 electrode 7 19.5.3 Disassembly 9F4 electrode 78 19.5.4 Maintenance 9F4 electrode. te ate z a 19 19.5.4.1. - Disaasembling ~ cleaning greasing... aD) 19.542 Reassembly of the electrode 79 19.55 Disassembly and reassembly ofthe discharge roll 279 19.6 BIKAPPA SIMPLEX MOUSSE. . 80 19.6.1 AIR-GAP adjustment. 19.6.2 Disassembly 76 electrode 19.6.3 Disassembly 9F4 electrode 19.6.4 Maintenance 9F4 electrode. 19.6.4.1 Disassembling — cleaning - greasing. 19.6.4.2 _Reassembly of the electrode pee i 19.6.5 Disassembly and reassembly of the discharge rolls. 83 19.6.6 Discharge roll adjustment... nnnsnnnsn so 84 19.7 BIKAPPA TUNNEL. 85 19.7.1 AIR-GAP adjustment ett 85 19.7.2 Disassembly 9F4 electtOde son : 86 19.7.3. Maintenance 9F 4 electtOde enon son 87 19,7.3.1 Disassembling — cleaning - greasing... ee 87 19.7.3.2 Reassembly of the electrode. eee 87 19.7.4 Disassembly and reassembly of the discharge FOll.vsscrssvssssnvonoencone 87 19.8 BIKAPPA SIMPLEX POLIMETAL...... - 88 19.8.1 AIR-GAP adjustment ‘ 88 19.8.2 Disassembly of the block of ceramic electrodes 89 19,83 Replacement of ayeletroge : 1988 Dinssnbiy and Seg he aR 19.9. BIKAPPA POLIMETAL 19.9.1 AIR-GAP adjustment 19.92 Disassembly ofthe block of ceramic electrodes. cmon IGBY 4FERRARINI & BENELLI COROKA TREATMENT 19.9.3 Replacement of an electrode 1994 Dissembly and reassembly ie dsargeo. 2 19.9.4.1 “Upper roll (R1)... : 19.942 Lower roll (R2) 19.10 BIKAPPA ROTARY 150. 19.101 AIR-GAP adjustment. 19.10.2 Disassembly 7F6 or SF6 electrode... 19.103 Disassembly and reassembly the discharge roll. 19.103.1 Upperroll (R1).. 19.103.2 Lower roll (R2) 19.11 ROTARY, SIMPLEX... 19.111 AIR-GAP adjustment . 19.112 Disassembly and reassembly ofthe electrodes... 19.113 Disassembly and reassembly the discharge rolls. 19.12. SUPER ROTARY, MAXI ROTARY and MAXI SIMPLEX. 1912.1 AIR-GAP adjustment 19.13 370 and BASIC 19.13.1 _AIR-GAP adjustment... 19.14 ATSL 80... 19.141 AIR-GAP adjustment... 19.15 POLIPLAST KAPPA PLUS UNO..... 19.15. AIR-GAP adjustment... 19.15.2 Disassembly and reassembly of the electrode single bar BU 19.15.3 Disassembly and reassembly of the retractile electrode type 20F4.5 19.154 Maintenance 20F4.5 retractile electrode 19.15.4.1 Disassembling — cleaning - greasing... 19,1542 Reassembly of the electrode 19.16 POLIMETAL 19.16.1 AIR-GAP adjustment... 19.16.1.1 Check the concentricity between electrodes and rol: 19.16.1.2 Fine adjustment 19.16.2 _ Replacement of ceramic electrode 19.17 POLIMETAL KAPPA PLUS UNO. 19.17.1 AIR-GAP adjustment... eit 19.172 _ Disassembly and reassembly of the block of ceramic electrodes 19,173 _ Replacement of a ceramic electrode 19.18 POLIMETAL KAPPA PLUS UNO (version without electric box) POLIMETAL KAPPA UNO 150. : 19.18.1 AIR-GAP adjustment. 1918.2 Disassembly and reassembly ofthe block of ceramic electrodes 19.183 Replacement of a ceramic electrode. 19.19 POLIMETAL KAPPA PLUS XL... 19.19.1 AIR-GAP adjustment. 109.19.2 Disassembly and reassembly ofthe block of ceramic electrodes 19.19.3 Replacement of a ceramic electrode. 19.20 TNN FLAT. 19.20.1 AIR-GAP adjustment 19.20.1.1 AIR-GAP chek on 19.20.1.2 AIR-GAP adjustment 19.20.2 Disassemble of the electrodes unit. 19.203 _ Electrode replacement. 19.21 TNN PIANO. : 1921.1 AIR-GAP adjustment ean 1921.11 AIR-GAP cheek s 1921.1.2 _AIR-GAP adjustment 1921.2 Replacement of a ceramic electrode... 19.22 ET 98..... centr IGRI :FERRARINI & BENELLI CORONA TREATMENT 1922.1 AIR-GAP adjustment. 136 1922.2 Replacement electrodes... 137 19.23 ET 117.. sin move 138 19.23. AIR-GAP adjustment. cia sande 19.24 ET TAD cccsssesnen ee area eat svsenteesenieussassinsen 139. 1924.1 AIR-GAP adjustment. ere sn 39 20. Measurement of treatment level. sennne 140 £201 PUTpOSe wrvnrnn 140 20.2 Procedure method... 140 20.3 Test Inks... ee Etenaaae Wl 20.4 Warnings... i ae 141 21, Troubleshooting . aerate Sr 142 QLD Malfunctions .ocsrn 142 21.2 Plant down problems — 146 212.1 Check the feeding ofthe ard. ese M6 212.11 0301-1/02 card.. : : - : 7 146 212.12 9703-DRIVER card, 146 21213 97038 - DRIVER=BST eard. nee 212.14 0802 ALDRV or 0901-ADM card 147 21.22 Diodes bridge checks. o Soha 21.23 iGBT module check and replacement cree 148 21.3 Treatment insufficiency problems... son 149 21.3.1 Verification of work process conditions. oo 49 2132 Composition ofthe material... - crac 149 21.3.3 Verification of TEST-INKS reliability : 149 21.3.4 Verification of treatment detection position. neseee 149 22. Maintenance program... 150 23. Advised replacements .. stan TB 24, Silicone sleeve replacement... 153, Bi CET cwcncansnscanernn sosuannesansnenecoassnes vee 154 25.1 Preamble. - aavanesesenin reesei sooo TED 25.2 Ozone (OP snnrnn aac accent tence _ 25.3. Effect of ozone on human health | (04. canicianee 154 25.4 Safety regulations. i 155 25.4.1 Workers? safety in the workplace. : . 155 25.4.2 Safety of external environment. Stack emission of ozone. eee iss 25.5 Oz0-NOI. i ASS 26. schemes, lectical and) scones $6. 7X ie ! \\ Any missing pages are referred to corona stations that are not within your field. eee) : eg MMR cenerstor IG BT :FERRARINI & BENELLI CORONA TREATMENT 2. USE OF THE INSTRUCTION MANUAL ] ‘This manual must be carefully kept in a place that is known and casily accessible to all possible users of the equipment. Read and make sure each operator reads this manual carefully and completely before installation, use, maintenance or disposal of the machine. Always check that the operator has fully understood the user regulations and the meaning. of any symbol on the machine. Do not remove or damage labels and writings. Most accidents can be avoided by following the instructions given below. Operations that may be dangerous for the operator are marked in the manual with the symbol: /: | \ Description of operation that may cause danger. [3._SYMBOLS DESCRIPTION ] LO Deflection risk. Move the hands from the nioving parts. Ae Electrical shock risk. Internally there are components in high tension. ; @ Ys \ Lifting points. conmon IGE :FERRARINI & BENELLI CORONA TREATMENT 4. GUARANTEE ‘The supply is guaranteed for 12 MONTHS from delivery date. During the guarantee period FERRARINI & BENELLI undertakes to replace free of charge and immediately, free its Romanengo premises, any parts that have defects or in any case are not suitable for perfect functioning of the equipment. Damages due to incorrect or improper use of the equipment are excluded from the guarantee. © Any guarantee interventions carried out on the customer’s premises shall be free of charge with regard to the spare parts and the hours required for repair, while travelling expenses, duty travel and board and lodging shall be at the ctistomer's expense. © The guarantee becomes legally null and void if the customer does not observe the payment methods, if the products are used negligently or inexpertly, if they undergo tampering and modifications or if the machine is subject to poor maintenance or is sold. + In no case envisaged by: this article may the buyer claim cancellation of the contract ot payment of damages. 5._STANDARD REFERENCES 5.1 Treatment station 5.11 European directives © 2006/42/CE © 2006/95/CE 5.1.2 Technical standards e EN 292-1 © EN 292-2 © EN 60204-1 + EN4I8 5.2 Generator 5.21 European directives » =2006/42/CE + 2006/95/CE + 2004/108/CE 522 Technical standards: * EN 292-1 “e EN 292-2 * EN 60204-1 + EN4I8 coer IGBT 7FERRARINI & BENELLI CORONA TREATMENT DANGER ZONES ] Ay, is Bs A AX AN 6.1 High voltage Contact with electrical parts under tension may cause serious damage. Given the high voltage in Corona systems (between 10kV and 30kV), lightning may be triggered even at a distance of 50 mm. In the Corona treatment systems the elements under high tension are as follows: © Electrodes In systems with several electrodes that foresee the possibility of distancing one of them, if an electrode is distanced it will not produce a discharge but will ALWAYS remain under tension and therefore in a risk condition. © Electrode holder bars © Insulators = Connecting cables from transformer to treater unit 6.2 Harmful gases ; During the Corona treatment quantities of ozone and other harmful gases, caused also by ‘the used material (film t6 treat), are produced. Given the harmfulness of these gases they must be conveyed away from the operators’ work areas, The user has to take care about the installation and the setting of the suction systems supplied with the Corona treatment station. 6.3 Moving parts ‘The Corona treatment systems consist of rolls, pistons and other moving parts that facilitate film feed. ‘All items of equipment are building in accordance with the most rigorous safety standards, but it is good practice to keep well away from moving parts. /y in fe MDAAA. common IGBT ‘FERRARINI & BENELLI aM ll CORONA TREATMENT [7__PURPOSE OF THE EQUIPMENT The CORONA TREATMENT system is an equipment for carrying out Corona Effect surface treatments and it cannot be used for different purposes or different materials from what foreseen in the supply contract. cenrmron IG BT ae=f | FERRARINI & BENELLI CORONA TREATMENT 8._GENERAL SAFETY STANDARD. _] G The envisaged use of the machine is given in chapter 7. Any use other than the use prescribed by the manufacturer may be dangerous for the operator The generator and the Corona treatment station, as they do not have any lighting system, have to-be installed in a lighting place of the’equipment as indicated in the regulations in force. For the maintenance, if needed, please use portable lamps. 7A. The voltage on the electrodes in the Corona treatment unit is between | / 1 \, 10+30KV. Acceding to the interior with discharge switched on is extremely | / ¥ \ aangerous. Even at a distance of 50mm, anomalous discharges may oceur, (__*_Sespecially if the potentially exposed person has wet or very damp hands. Voluntary deactivation by the opérator of the safety systems (sensors) that lock the enerator is highly dangerous and is the exclusive responsibility of the operator inasmuch as it is absolutely excluded in the machine construction phase. ‘All maintenance and adjustment operations must be carried out with the machine completely stopped and switched off. ‘The entire Corona treatment unit must be well earthed to avoid undesired voltages. Hook up the treater, the supply cables and the earth cable before powering up the equipment. Please foreseen periodic checks of the earthing gystem and of the continuity of the protection circuit on the Corona treater. cE Any tampering with the protective devices, the safety sensors and the sound and visual alarms is the exclusive responsibility of whoever carries it out, FERRARINI & BENELLI decline all responsibility for any tampering with or exclusion of the prescribed saféty devices. G Fach treatment unit produces ozone (see chapter 25) through Corona effect discharge. Ensure correct ozone evacuation by checking periodically the fans, the exhaust ducts and eventual control systems (Sensors to detect proper air suction). The maximum concentration permitted by the regulations is 0.1ppm, measured where the person closest to the treatment unit is positioned. For ozone extraction tubes use stainless materials such as PVC, aluminium, stainless steel or plastic (see paragraph 13.4.3). For any other eventual gases produced during the Corona conmor IGBI ‘ yFERRARINI & BENELLI GORONA TREATMENT treatment please remind to remove them from the working zone as for the health and safety regulations, BH Place barriers or gates around the treatment station, When they are opened they ‘must interrupt high voltage discharge and stop moving parts in order to prevent personnel from crossing danger zones. GH During work processes or maintenance in the vicinity of the machine it is advised to lock the general cut-out at OFF to avoid dangerous situations for the operator. & To avoid dangerous situations for the operator, do not disconnect the line cable if there is power supply from the switchboard, GB For safety reasons’ the machine and accessories must be used solely for the purpose they were designed for, and the safety devices supplied or recommended by the manufacturer must be used, (EF Modifications to the machine and its accessories are prohibited, BH Should there be any doubt about safe and correct use of the machine or accessories, always consult the manufacturer before using the machine. BH Cables must be disconnected for handling and moving, \, On opening the equipment after a working period the power circuit may remain under tension for two minutes. 7 /% ( (GH Do not use liquids or foam-producing extinguishers. ‘ic film, paper and all materials that may be given Corona effect treatment may become charged with static electricity. The removal thereof should be provided for with electric or passive antistatic bars such as catbon bars, suitably earthed. . GH The Corona discharge generates heat on the material surface; we suggest to not use the equipment at high power with low working speed in order to avoid risk of damage the material and of fire trigger. & The connection cable between the generator and the THF can not be modified on length, unless agreed with FERRARINI & BENELLI. cB The equipment, unless a different prescription, is not adapt to be installed in fire risk and/or potentially explosive zones. @> FERRARINI & BENELL! corona treatment equipments have a noise level inferior to the law threshold. ‘The custottier has t6-verifyitie-noise level in the installation place and, in case of overcoming of the allowed threshold, foresee a noise destruction system. connor IGBY vFERRARINI & BENELLI CORONA TREATMENT f= GF Install the equipment in an accessible zone for use and maintenance. In case, foresee the predisposition of catwalk, footbridge, access stairs and parapets to prevent falls or other helpful things to allow the execution of operations in safe condition, @ The Corona treatment equipment can generate heat inside the generator and the THF. _ In the generator is installed a temperature detect sensor that stop the discharge when the heat exceed the fixed threshold of 70 or 80°C according to the model. In se it is necessary to access inside the generator, after a long use of the equipment, it is suggestable to turn off the discharge leaving the panel feed supply and wait some minutes to allow cooling of internal components. The THF is protected by an external cover to avoid accidental contacts with parts that can reach temperature of 60-70°C. 8.1 Open/close of pneumatic system (if provided) In case of equipments that have open / close pneumatic system of the electrodes that exposes eventual operators to a crushing risks foresee the segregations of movement parts to avoid these risks. The open of the eventual movement gates to enter in the area have to forbid the feeding of the pneumatic system to block eventual unwanted open / close operations. For the maintenance ‘The pneumatic system do not require interventions for ordinary maintenance. In case it is necessary to work on the pneumatic system, isolate the air feeding circuit before make any operations. connor IGBY 13FERRARINI & BENELLI CORONA TREATMENT 8.2 Ozone All the Corona treatment equipments have an evacuation control system based on the start cheek of the suction fan, Some models foresee also flow indicators mounted on the suction pipes of the treater (included or optional depending on the models). In case of equipment without these indicators it is at custonier care to guarantee a correct evacuation of the produced ozone and to verify the efficiency of the all suction equipment. Eventual control systems added from the customer has to be integrated with the protection circuit already included in the equipment. In case of accidental ozone leaking in working area, turn off the Corona discharge and move away from the contaminated area. ‘The ozone concentration perceptible by the typical produced smell is generally much more lower than the risk threshold. For other details see chapter 25. 8.3 Motorication of the discharge roll The rolls installed on the Corona treatment stations are generally idle and moved by the film that pass on them; on fequest they can be provided with power take-off or inverter- motor installed in axis to the roll and control by the customer line. ‘The rotation can change from 1-2 rpm until 1000 rpm. In case of inverter-motor. or power take-off it is prohibited to remove the provided fixed protections. ‘9, INSTRUCTIONS FOR EMERGENCIES SITUATIONS In the case of emergency use only CO; type extinguishers. / \\ Do not use liquids or foam-produeing extinguishers. / \ sed cornmnorn IGBY ie28 FERRARINI & BENELLI CORONA TREATMENT [10 GENERAL INFORMATION 10.1 The purpose of the surface treatment Generally, plastic films have inert and non-porous chemical surfaces, with low surface tensions that make them non-receptive to anchoring of substrates such as printing inks, adhesives and coating. In order to obtain a surface that is apt to be suitably wet with liquids, plastic material surface energy must be higher than liquid surface tension. For example, a printing ink with 30 dyne/om tension would never wet or adequately bond with a material having surface energy lower than 37-40 dyne/om. (“10 points rule”) Surface tension of virgin ‘Average surface tension required for materials without additives different applications MATERIAL Dyne/em “APPLICATIONS | Dyne7em PP, OPP. BOPP 29-31 rinting — solvent base inks [38-42 | PE 30-31 Printing — water based inks | 4a-48 PS 38 [Coating = Laminating 38-44 | ABS 35-42 No noise - "36-38 PA <36 PMMA <36 z PET a-48 as = PVC 39 PC 46 E el NYLON, 33-46, CONTACT ANGLE ‘CONTACT ANGLE CLOSED TO 180° CLOSED TOO" LOW SURFACE TENSION HIGH SURFACE TENSION ‘Amongst different plastic films, polyethylene (PE) and polypropylene (PP) ones have the lowest surface energy and therefore undergo corona treatment more often, in order to enhance their adhesion properties. However, corona-effect surface treatment is not limited to these two materials and can also be used to enhance adhesion properties of basically all plastic materials as well as some materials of other nature as aluminium and paper. ‘All substrates, plastics films, paper and aluminium provide best surface adhesion when treated at the time of their manufacturing. ‘Adhesion is of a chemical-physical nature determined by the two materials intermolecular attraction force. connor IGBI ieFERRARINI & BENELLI GORONA TREATMENT Several properties peculiar to polymers are involved in this complex process linked to adhesion: chemical composition (nature of mono-metric units, presence of lateral groups, polarity, etc.); molecular stricture (tacticity, main chain symmetry, reticulations, etc.) and structure properties (crystallinity, orientation). Without going into details of adhesion, let us only point out that molecular attraction forces (@s dipolar interactions, hydrogen bonds, etc.) have an action fange of few A (1 Angstrom = 10 * micron = 10 7 mm), so the basic problem in all adhesion processes is to bring support film molecules in close contact with those of the material which must adhere (ink adhesive, etc.); in other words, the film must be completely wettable. 10.2 Methods of improving the surface treatment The four methods used for surface treatment are the following * Corona discharge © Priming ® Cleaning with acid or plasma Flame treatment Priming is still frequently used alone or combined with Corona treatment to enhance surfaces wettability, increasing their capacity to bond with solvents, adhesives, coating and extrusion coating, Another method used almost exclusively in extrusion coating is the ozone treatment. Flame or acid/plasma treatments are frequently used for injection moulded patts. 10,3 How to obtain the Corona discharge’s effect A corona treater is essentially made up of a high frequency generator (A), a step-up ransformer (B) to which a fixed straight electrode is connected and an electrically ground roller coated with insulating material (C). cen IGBY - 4eR FERRARINI & BENELLI CORONA TREATMENT Glow discharges leading to film activation take place in the AIR-GAP between film and electrode. In fact the corona treating effect is based on bombarding the surface of a polymer with electrons. The process that takes place is basically a collision ionisation, meaning that some ion, always present in the air, accelerated by the applied electric field, hits some neutral molecule causing its ionisation. The new charged particles formed in this way, may in turn ionise by collision other molecules, and the process called “collision ionisation” builds up rapidly, eventually causing the so-called air dielectric braking: air molecules transmit light and react in part ozone and nitrogen oxide. When electrons come into contact with polyethylene, for instance, their energy is such as 10 break the hydrogen-carbon or carbon-carbon bond. The radicals thus formed react with the corona discharge, mainly in oxidation, Functional groups formed in this manner are polar and therefore provide the base for adhesion of printing inks, lakes, adhesives, etc. Dielectric material on the roller has a specific function: ie. distribute discharge uniformly along electrode’s surface. Actually, without this, discharges would be brought about in some points as “small lightning” and with such energy able to damage the film. 10,4 Corona’s factors and parameters ‘As mentioned, ultimate goal of every surface treatment system is to increase product surface tension, measured in dyne/em as well as enhancing wettability and surface adhesion properties. Corona treatnient systems achieve such results by applying a given power, for a given time on the surface This power parameter in time is measured in watt density, defined as ‘Watt*minute/m’. ees a NL * EN DS [W*min/m?] = Watt power density P[W] Supplied power L[m] = Film width V [m/min] = Line speed NL = Number of sides to be treated (1 or 2) cn on IGBT MmFERRARINI & BENELLI CORONA TREATMENT Not all materials or substrates react in the same way to corona treatment. Some materials, such as certain polyesters, receive treatment without problems and show rapid surface tension increase using relatively low power intensity levels, Other materials, such as polyethylene instead, receive treatment with more difficulties yet show significant increase in surface tension using medium-low levels of power intensity. Finally, some materials, such as polypropylene, are difficult to treat and may show only moderate surface tension increase using relatively high power intensity levels. Reaction of a material to corona treatment is also affected by the different manufacturing process parameters. It is known that extrusion, extrusion coating, lamination by extrusion processes require different treatment levels to reach acceptable product and production quality levels. Nevertheless, it is less known that the type of manufacturing affects reactions of a given substrate to corona treatment. These differences are due to the following elements: + Variation in molecular structure as result of the extrusion process. * Substrate temperature at the time it enters corona treatment unit. © Location of corona treatment unit relative to the point of extrusion. It’s very important remember that the nude material reactions to the Corona treatment depend on the additive charge, expressed in parts per million (ppm), contained in the film. The first consequence of an elevated additive charge is that of requiring an increase in power density to increase the film surface tension by a given amount, Secondly, an elevated quantity of additive in the film reduces material's capacity’ to maintain corona treatment effect in time. This is caused by additives tendency to group together or migrate to the surface and mask corona treatment effect. It is commonly believed that additives will migrate more rapidly towards a film surface, which has been treated. State Dyne per W'minim? “0 60 80 100 220 wren? a= 300 pom == --600 ppm 1200 ppm common IGBY - 1FERRARINI & BENELLI CORONA TREATMENT Another important factor that influences the corona treatment value on the film surface is time. Treated surfaces progressively lose treatment with passing of time. This is always true for all treatment methods and all films, even non-additivated ones. The amount of treatment loss depends on the type of film, treatment level, type of treatment additive quantity and elapsed time. Unfortunately some of the beneficial results obtained by the corona treatment degrade after treatment. Main reasons: «Rubbing of the treated surface on idle rolls, drummer, reel, ete, «Contact between treated side and opposite side, © Quantity of slip agents It should also be noted that once final processing, such as printing, coating or lamination is, over; anchor enhancement obtained with corona treatment remains stable. In other words, ink will not come off after a period of time and the two substrates will not delaminate. Treatment “loss” occurs between the period of time going from treatment to consequent converting process. Yet an elevated initial treatment level is not a solution to the problem. In fact there are negative consequences as, per example, the blocking effect of the reel, weakening of the material, backside treatment, welding problem, etc. : It must also be said that if a material contains added components such as additives and slipping agents, treatment at the time of use is more efficient if material has already been treated at the time of extrusion. This case is called treatment restore or renewal. Treatment renewal is that situation in which a film that had previously undergone treatment is treated again in-line with corona process before completion of converting process. For instance, a film already treated at extrusion could be treated again in lamination, coating or printing process. Experience proves that, with a given surface tension increase; retracting pre-treated films requires less power intensity than treating a non pre-treated film, Moreover some non pre- treated materials do not increase their surface tension even if very elevated power densities are applied. This is due to their molecular structure and slipping barrier or additives that migrate to the film surface, reducing surface tension. GENERATOR IGBr teFERRARINI & BENELLI CORONA TREATMENT 11. GENERATOR SPECIFICATIONS IL1 Supply The system has to be fed in accordance with what has been decided in order phase. Current absorption on the supply line depends on the model used (for more details see 11.3). IL2 Protection ‘The equipment includes a safety circuit which cuts out the power part in the case of sudden absence of supply voltage. i ‘The apparatus is protected by a magneto-thermal switch. All the internal service lines are fuse-protected. 11.3 Identifying technical data IGBT TECHNOLOGY CORONA GENE! 5 “Gtsim | GTS 3M j GTS 1M-UC Ts sm-uc Height (mm). Dimensions Degree of protection | Weight (Kg) i Noise a <70d8_ Installed power |) f.2)kVA 22KVA 30KVA_| ae Tension 1x 230 V or different upon request Frequency “60/60 Hz | a Power TOW 27 kW Output ed Frequency 13.430 kHz connor IGBY aFERRARINI & BENELLI GORONA TREATMENT ae > STLX -1cpt TecHNoLocy ets | cts | GTs | cts STLX | 8TLX | 10TLX | 127LX T-Uc | 8T-UC | 10T-UC]} 427L-UC Dimensions Degree of Weight (Kg) Noise Installed Power supply Output Dimensions Degree 0 IP 43 Weight ~ 130 <70d8 16.0 kVA | 18.0 KVA | 20.0 kVA different upon request 50/60 Hz 44.0 KW] 10.0 KW] 18 13 +30 kHz Power supply —— + Output 0 kW] Following in the handbook for the models M-UC and T-UC please refer to the correspondent M, TLX or TMX. cenernton IGBT erFERRARINI & BENELLI CORONA TREATMENT 12, GENERATOR LAYOUT ] el See 12.1 Composition ILI Single-phase model GTS M * Switchboard unit (where applicable) ‘+ Single-phase generator unit SEHERATOR M + High Voltage Transformer Unit (THF) 1) The Single-phase Generator Unit is essentially a frequency converter from 50/60 Hz. to 30.000 Hz, equipped with an ignition cut-out and power adjustment controls, and consists of: © Switchboard: © Main switch [as). © Where applicable, ozone suction fan magneto-thermal switches [@M2] [M3] © Where applicable, discharge rolls cooling magneto-thermal switches [QM] [QMs]. © Where applicable, motorization discharge rolls magneto-thermal [M6] [QM7] ‘© Where applicable, pressurisation magneto-thermal switches [QM8]. © Hole of entry feeding cables and junction-box. In case of M-UC: © Where applicable, fuses suction ozone fans [FV4-1;-FV2-4; FV3-1] [FV1-2; FV2. FVv3-2]. © Where applicable, fuses cooling fans of the discharge rolls [FV4-3; FV2-3; FV3-3] [FV1-4; FV2-4; FV3-4]. © Where applicable, fuses motorization discharge rolls [FV1-8; FV2-8; FV3-5] (FV1-6; FV2-6; FV3-6) © Where applicable, pressurization fuses [FV4 2-7; FV3-T] © Generator stand © Switchboard cooling fans [V4] with filter and grille, © Generator magneto-thermal switch [1A] (© Sensors connectors. ° Connexion connector of power High Tension Transformer cable. * Operator interface: © 9701-FRNT card [N1] and related control panel. © Sound alarm. © 0301-1/02 card [N2]. © Auxiliary circuit: ©” Supply line EMC filter [Usps -usianise bah © Control circuit protection fuses [F4] - . - [F8} © Transformer for electronic circuits 230 / 9-18-9-15-24 — 100VA [T¢1] conor IGBY 2FERRARINI & BENELLI CORONA TREATMENT © Power Circuit: ° 0000000 ° Power circuit actuator [KM]. Diode bridge [Ve]. Frequency condensers {€2] or level condenser (C1] iGBT module [E1-E2] mounted on waster. Thermal sensor threshold 70°C [T]. RC filter group. [C3-R3-C4]. Induetances [L] and [L4] 9703-DRIVER edird [N3] and 0901-ADM [NA]. ‘Ammeter transformer 50/100 [TA1] [TAZ] To localise the various components see 12.3.1. 12.1.2 Three-phases models GTS TLX and TMX een «Line transformer unit (where applicable) ‘ © Three-phase generator unit © High Voltage Transformer Unit (THF) 1) The Three-Phases Generator Unit is essentially a frequency converter from 50/60 Hz to 30.000 Hz, equipped with an ignition cut-out and power i f ferme | GENERATOR Tux adjustment controls, and consists of: © Switchboard: ° ° ° ° ° ° oy 000000 Generator stand. Main switch (QS). Generator magneto-thermal [QM4] switch [laM1). Where applicable, ozone suction fans magneto-thermal [QM2] [QM3] switches [lam2} [rams]. ‘Where applicable, discharge rolls cooling fans magneto-thermal [QM4] [QMS] switches [JQM4] []QM5] ‘Where applicable, motorization discharge rolls magneto-thermal [QM6] [QM7] switches [M6] [17]. Where applicable, pressurisation magneto-thermal [@M8] switch [!@M8] Hole of entry feeding cables and junction-box. Equipotential bar. Switchboard cooling fans [V1] [V2] [V3] with filter and grille. Sensors connectors. Connexion connector of power High Tension Transformer cable. case of T-UC: Where applicable, fuses suction ozone fans [FV1-1; FV2-45 FV3-1] [FV1-2; FV22; FV3-2] Where applicable, fuses cooling fans of the discharge rolls [FV1-3; FV2-3; FV3-3] [FV1-4; FV2-4; FV3-4]. ‘Where applicable, fuses motorization of the discharge rolls [FV1-5; FV2-5; FV3-5] [FV1-6; FV2-6; FV3-6). Where applicable, pressurization fuses [FV1-7; FV2-7; FV3-7). GENERATOR IGBr 23FERRARINI & BENELLI CORONA TREATMENT * Operator interface: o° 9701-FRNT card [Nt] and related control panel. © Sound alarm. © 0301-1/02 card [N2] © Auxiliary cireuit: © Supply line EMC filter [J]. © Control circuit protection fuses [F4] - .. - [F44] © Transformer for electronic circuits 230 / 9-18-9-15— S0VA [T¢4] © Transformer for services LINE IN / 230-24 ~ 3S0VA [T¢3]. © Power Circuit: © Power circuit actuator [KM1]. © Diode bridge [ve] Frequency condensers [62]. iGBT module [€1-£2] mounted on waster with forced air [V4] Thermal sensor threshold 70°C [T]. RC filter group. [C3-R3-C4). Induetance (U). 9703B-DRIVER+BST card [N3]. 0302-ALDRV card [N4]. o Ammeter transformer 50/100A. [TA1] [TA2] To localise the various components see 12.3.2 and 12.3.3. 2000000 2) The High Voltage Transformer Unit (THF) coisists of: * Sealed cylindrical aluminium container. © Oil insulated winding. * Closure flange with insulators. © Pressure safety valve, con#or IGBY caFERRARINI & BENELLI CORONA TREATMENT 12.2 Characteristics © Reliability The component working conditions are selected below their admissible limit. The circuits ate effectively protected both from surge variations in mains supply voltage and from stable variations far greater than the admissible limits on mains supply networks. ‘The equipment is protected against the possible lack or break of each phase; in this case the working stops. The equipment is cooled by foreed air circulation. «© Tropicalization . The generator support housing and all the components are protected against conditions of tropical humidity. © Mains network protection NOISE: all models are equipped with a standard mains filter that prevents the propagation of any mains disturbances determined by the functioning of the generator. PROTECTION: any short circuit in the equipment cannot be propagated externally. 12,3. Interior views 12.3.1 Single-phase model GTS M ‘Switch view GENERATOR IGBr eFERRARINI & BENELLI 12.3.2 Three-phase model GTS TLX Disposition shelves view and control panel cenenntor GEST 26FERRARINI & BENELLI 12.3.3 Three-phase model GTS, and controt panel GENERATOR IGBYFERRARINI & BENELLI CORONA TREATMENT 13. INSTRUCTIONS FOR WAREHOUSING, DISPOSAL, HANDLING AND INSTALLATION On delivery of the machine, please make sure that the packing is not damaged and the unit doesn’t show any sign of impact. On the contrary, please inform the FERRARINI & BENELLI Technical Service For generator weight and size please see paragraph 11.3 13.1 Warehousing ‘The warehousing temperature must be in the range -25°C e +55°C. For periods shorter than 24 hours the warehousing temperature can reach +70°C, Once the machine has been unpacked, it must be stored in a dry room. 13.2 Disposal Please, do not disperse the unit or its components in the environment. Arrange for a right separation according to the kind of materials forming the unit in order to allow a new reuse or a differentiated disposal. In any way, please, refer to local legislation for disposal of waste. ‘The main materials forming the unit are: 13.2.1 Treating unit MATERIAL : COMPONENT Steel — Iron a Odds and ends “Shoulders Aluminium Rolls Frames Odds andends Bronze ‘Odds and ends | Plastics (Lexan) Protections | Tefion Supports Ceramic Covering of the roll or electrodes Silicone Covering of the roll | Dielectric off = THE. al 13.2.2 Generator ; MATERIAL COMPONENT Steel Transformer frame and nucleus | Aluminium Dissipeers Se Fans ce ; Handles oF BUC Rae paint Cables Insulated copper by glass fibre and resin Transformers connor IGBT 28FERRARINI & BENELLI CORONA TREATMENT 13.3 Handling 13.3.1 Treatment station ‘Any FERRARINI & BENELLI treatment unit can be hoisted by lift trucks using chains hooked up to the ringbolts supplied. You must use all available ringbolts. Be sure to check that the chains are suitable for bearing the load (weight is stated in the attached documents). Keep well clear of hoisted loads. Do not let the load swing Avoid unbalanced loads. 13.3.2 Generator Any generator can be hoisted with lift truck; for TMX model, we suggest you to remove the base front and rear black panels and use fork-lift truck, / / ]\, cables must be disconnected for handling. ¢ 13.4 Installation 13.41 Treatment station «Fix the treatment unit firmly to the prescribed support structure in such a way that it does not move. Remember to connect also the support structure to an electrical earth cable, © Once the treatment unit installation position lias been identified, check that the rollers are perfectly on the level and parallel to the other rollers of the machine in order to avoid shifting of the film. © Level the treatment unit perfectly, both longitudinally and transversally. ‘IDE VIEW ‘VIEW FROM TOP FRONTAL VEN =|) =] + Leave appropriate space for opening the hoods and for maintenance personnel to gain access. * Check the electrode-roller distance (AIR-GAP): © For systems with silicone coated roller it must be-1.Smm. © For systems with ceramic coated roller it must be 1.3mm. ‘©. For systems with ceramic electrode it must be 1.3mm. conor IGBT »FERRARINI & BENELLI CORONA TREATMENT + In case of treatment station equipped with pneumatic system to move groups of electrodes, place control switch board in a visible area to view the equipment in order to guarantee an execution of the operations of open / close in safety. © Engage the air pressure by adjusting pressure where necessary until (J there is a gentle and linear opening and closing of the pneumatic action that moves electrodes, rollers and structure. This operation should be carried out only in the case of units supplied with pneumatic movement (standard pressure: 6+8 bar) * If the treatment unit is in the pressurised version, connect the auxiliary pressurisation fan(s) to the relevant terminal board located in the electrical switchboard © For special treatment units see chapter 19. + Incase of separated THF from the station: © Connect the earth cable mounted on the THF side to the fixing point on the station indicated with the symbol @. © Connect eh high tension cable that exits from the THF to the entry point of the high tension of the station (see prearrangement scheme 26). The high tension cable has to keep completely insulated to avoid accidental contacts and keep away at least 5 em from all the earthing metallic part to avoid short circuits. By As AS conn IGBr aFERRARINI & BENELLI CORONA TREATMENT 13.4.2 Generator + Place the generator in order to guarantee that the controls and the visualisations can be easily accessible and be external to the segregation areas of the equipment. + Position the transformer supply socket (or the electrical switchboard supplied on request) at the most suitable point and hook up to the three-phase line. + Ifyou wish to connect a cut-out before the socket, do not use a switch with fuses but rather a magneto-therinal switch. + To avoid repeated interruptions of discharge vou are advised not to connect the generator supply line to the electrical switchboard of the machine (extruder, printing, coupler ete.) but rather to take supply voltage directly on the main distribution line (“Bus duct”) at a point at least 5 metres away from the machine. The reason for this is that analysing the supply voltage diagram within the machine electrical switchboard much interference is noted which could cause disturbance to the generator. «Leave the indicated distance as show in the drawing here below to permit the exit of cooling aif. Y Y Z G aes ] Y g" SP y q 7 gpucs | ] 7 ] Z j Z Z | ) Yo\ Y Ze G F Ze Y %, LG LD Zi GTsM GTS TLX GTS TMX © Install the generator in_a_zone with temperatures not greater than 40°C to avoid cooling the internal components with air that is already hot. «No components are sensitive to variations in altitude, « Given the voltages produced by this equipment, you are advised to connect both the generator and the treater unit to the earth wire created with points to ground in accordance with the accident prevention regulations in force. + Camry out measurement of the mains voltage, checking that it is within the interval + 10%. + Do not use metal conduit for the high frequency cable connecting the generator to the high voltage transformer. There could be power losses due to “Skin Effect” You are advised to keep this cable at least 50 mim distant from the cable connecting the interlock circuit between treater unit and generator. cnmon IGBI -FERRARINI & BENELLI CORONA TREATMENT 13.4.2.1 M model If supply switch board is NOT envisaged: ‘© Connect the plug to a socket with 230V mono-phase line voltage. * Ozone suction fan comections re THE CLIENT'S RESPONSIBILITY and are external to the generator. If the supply switch board is envisaged: © Connect 400V three-phase line + neutral voltage to the magneto-thermal of the supply switch board, © Connect the fan supply cable (not supplied) to the switeh board magneto-thermal switches (there are as many magneto-thermal switches as suction fans), * If envisaged, connect the suction fan control plug ftom the switch board to the socket on the back of the generator. © Connect the interlock cable. * Connect the high voltage transformer connéctor to the generator. Interlock socket & Interlock ED) plug conor IGBT aFERRARINI & BENELLI CORONA TREATMENT 13.4.2.2 GIS TLX and GTS TMX model © Connect the 400V three- phase line (or other three- phase voltage if specified) to terminal board XT4. The supply cable is connected DIRECTLY to the incoming terminals of the cut-out / switch and to the equipotential bar. ‘* Earthing of the equipment by means of the ground conductor of the supply cable is, always obligatory. Connect the earth to the equipotential bar. * Connect the ozone extraction fans, the pressurization and/or the motorizations to terminal boards XT2, XT3, etc. (cables_not supplied). Check that the blade rotation direction is correct. If not, invert two of the three fan power supply phases. Interlock Interlock socket plug Power - Power socket plug ‘© With the special connector, connect the high voltage transformer to the generator for power connection. © Connect the interlock cable to the generator. This cable supplies all information concerning sensors and related alarms. . GENERATOR IGBr _FERRARINI & BENELLI GORONA TREATMENT 1343 Ozone suction For electrical connection of the ozone suction fans, follow the instructions in point 13.4.2.1 As regards the air conveying lines: for M model and in point 13.4.2.2 for TLX and TMX models. [oeuwvery | DELIVERY The intake tube must be connected axially to the fan and the delivery tube must be connected to the outlet tangent to the blades, ‘The intake tubes incoming to the fan must not be longer than 1.Smt (MAX 2 mt) and must have no elbow bends, ‘The outgoing delivery tube to the fan must remain straight for at least Imt before being curved in any way, so that the air can gain speed without obstacles. ‘The delivery tube must be no longer than 10 mt between the fan outlet mouth and the evacuator and/or the wall ot roof of the premises if exempt from the obligation of ozone extraction. It may exceed 10 mt, up to a maximum of 15 mt, if the tube is straight without any curves whatsoever. If there is central tubing that collects the various exhausts, its section must be equal to the sum of all the sections of the delivery tubes that access it, and it must be completely airtight to avoid ozone leaks: Entry of the delivery tubes into the conveying tube must always be 45°, Absolutely avoid T-junctions in order to prevent turbulence and flow deviation, If the overall length of the tubing between the treatmeiit station and the evacuator is greater than 10 mt, loss of load should be checked and if necessary another fan used in series, of the same capacity as the one already installed. If there is a conveying tube it must be supplied with a fan whose capacity must never be less than the sum of the capacities of the fans upstream that force air into the eonveyor. If there are intake tubes in parallel it is best if they are of the same length to avoid unbalancing the suction systems. The slotted vacuum tubes inside the treatment station must be periodically cleaned and the intake slots must be free of detritus and dust. Use plastic or anti-oxidising tubes because ozone-rich air is corrosive. Moreover, smooth or only slightly rough materials are preferable. See the installation examples (paragraph 13.4.3.1). ‘SUCTION GENERATOR 1GBT 4€& FERRARINI & BENELLI CORONA TREATMENT 13.4.3. Examples of ideal evacuation ‘The layouts of the individual elements in the diagrams on the-following page are purely indicative. However you are advised to seek a solution as close as possible to the ones suggested and, as far as possible, not exceeds tube lengths. ‘The shorter the tubes the better the yield of the entire evacuation system will be. N.B.: In calculating tube length, consider one metre for every 90° curve and half a mete for every 45° curve. LOAD LOSSES (IN MM.) FOR EACH METRE OF SMOOTH TUBE IN FUNCTION OF FAN CAPACITIES INTAKE OUTPUT 4 TUBE 80 100 125 150 | 260 | 200 | 260 Ne nes} 1/2] 4/2} 4} 4} 2]3]4} 4} 2]t[ +]? 400 | 10.00] 2.00 | 0.31] 051| 010] 100/020] oo7{oosfo4o] - | - [ - | - zx [800 |21.00| 4.00 [0.70 | 1.40 | 022 | 2.00 | 040 | 0.48 | 0.07 | 4.00 | 0.18 | 0.07 | 022 | 0.07 § s | 7200 |75100|15.00| 2.60 | 6.00 [080 | 650 | 150 | 050 | 025 | 320 | 0.88 | 0.26 | 060 | 0.25 = [2000 | - [40.00] 7.00 |13.00] 2.20 [24.00] 4.00 | 1.60 | 0.70 | 800 | 1.60 | 070 | 220 | 0.70 | & [3000 | - | - |15.00]26.00] 4.90 [50.00] 8.00 | 3.20 | 1.50 |20.00] 4.00 | 1.50 | 4.90 | 1.60 4.000 | - | - |2600|4800].7.50| - |15.00] 5.80 | 2.60 [36.00] 6.50 | 2.60 | 7.60 | 2.60 Fan lift loadless 400 m*/h (APF20): 80 mmyz,o Fan lift loadless_ 600 m*/h (APF30 or MS28): 150 mmy,0 Fan lift loadless 1200 m’sh (APF35 or MS36): 200 mmy,0 Fan lift loadless 2000 m’/h (APF40 or MS40 or MSPR40): 180 mmu,0 Fan lift loadless 3000 m*/h (RM402): 250 mmy,o Fan lift loadless 4000 m’sh (RM451): 250 mmo Double the load loss values in the table if non-smooth tubes are used (flexible spiraled). The sum of tubing load losses must not exceed 50% of the no-load fan lift. In the case of a limit condition (more than 50%) you are advised to increase the tube section, Accurate dimensioning of the whole evacuation plant is of fundamental importance inasmuch as it could have negative influences on correct functioning of the treatment station; for example: # Dispersal of ozone into the environment. © Insufficient cooling of the electrodes: * in aluminium, with consequent uncontrolled dilation such as to cause creeping of the film and/or absence of treatment. + in ceramic with consequent overheating and possible breakdown. canon (GBT sFERRARINI & BENELLI CORONA TREATMENT 3 j ; 23 z 2 Be sore nee 1 2 | tn ee tet noe Seal se oon 25. wx von 25 ur Speailta es Dam 80-100" 125 AccoRaING TO THE TREATUCNT TC 34 Fuxeue “DIRECTION OF AIR FLOY——, To EVACUATION PLANT Tarn 600 vant {fi deacsea moe SPRNLED TUBES Sem. =100-125 | ‘ACCOROING TO THE ‘ramen Tee nie he. 1 sugars TBE De, 200, FOR GACH Fa 25 WF ue SUPPLENENTRY 6 a we GENERATOR IGBrFERRARINI & BENELLI CORONA TREATMENT 14, INSTALLATION VERIFICATION Hi Ht STATION Execution of fixing holes on your plant. YES | NO Creation of adapting plates for fixing (where requested). YES [NO (Creation of structures or support brackets for fixing (where requested). YES | NO. ‘Treatment unit positioning and fixing. YES | NO Preparation of return rollers for feeding. YES _|_NO Preparation of pneumatic system with tubes and connectors. (**) YES | NO ‘AIR-GAP check: 1.5 mm for silicone coated rollers. ; wee ling 1,3 mm for ceramic coated rollers. FANS AND/OR OZONE EVACUATOR, Fan positioning and fixing. YES |_NO Creation of treater unit — fan tube for PRESSURISATION (where] yng | xo necessary). (**) Creation of fan - treater unit tube for ROLLER COOLING (where YES no | envisaged). (** | Creation of treater unit — fan tube for OZONE SUCTION. (*) YES | NO [Creation of fan ~ evacuator tube for OZONE EVACUATION (Where yes | No envisaged). (***) Creation of tube from the fan (or from the evacuator) for AIR) vi | No EVACUATION (where envisaged). (*) and (***) GENERATOR Generator electrical cable preparation and connection (****). YES | NO Fan electrical cable preparation and connection (****), YES | NO ae electrical cable preparation and connection (where envisaged)! yp5 | xq Preparation of channelling or binding of transformer, interlock and push-| 36 | 19 button panel cables SEPARATELY from any cable in your plant (****), (©) For examples see the preparation diagram 13.4.3.1, (**) For sizes and type follow our specifications as per the preparations diagram on the last page. (***) For examples of preparations diagram in the evacuator manual (#***) For the electrical connection between generator, station and fans, follow the rearrangement scheme (see 26) GENERATOR IGBYr ae@® FERRARINI & BENELLI CORONA TREATMENT 15. GENERAL INSTRUCTIONS / For safety reasons, the unit and the accessories must be used only for the J \ purpose they have been built for and al seeurity devices supplied and advised \ by the manufacturer have to used. Changes in the machine and its accessories (__*__Sare not allowed, In case of doubts about a safe and correct use of the unit and of its accessories, please always consult the manufacturer before using the unit. J /\_ In case of treatment stations equipped with roll with silicone cover, when ue 1 \\_ it is not necessary to treat the material, DO NOT use the discharge roll as \ an idle rollin order to avoid that the creation and store of static charges | (___dmay damage the covering by silicone. In case it is necessary to use the discharge roll as an idle roll, mount an antistatic bar | near the share of roll where the material doesn’t pass in order to remove the discharges that accumulate on the roll itself. 15.1 Generator start-up procedure 1) ‘Throw the generator main switch IS: * FOR MONO PHASE GENERATOR (M): where applicable the switch, throw the generator main switch QS and all the magneto-thermal switches (fans and motorizations) GMa, ete, and throw the generator main switch 1A, * FOR THREE PHASES GENERATOR (TLX or TMX): throw the generator main switch QS, the feeding generator switch JaM1, and all switches concemed " the suction ozone fan, cooling of the roll, pressurisation and motorizations (where applicable) !QM2, 1QM3, IAM, IGMS, etc, On the front panel all the switches lamps and the display will light up and the intemal microprocessors start 2) Set all the discharge rollers turning. 3) Where present, check that all the protection hood doors are closed. 4) Check that the electrodes are in working position, 5) If the treater unit is equipped with pneumatic movement for opening and closure of the electrodes, rollers or structure, carry out the closure operation by pressing the CLOSE button (positioned in the special box connected to the treater unit box, to be placed in the most convenient location). y 6) Activate all the envisaged suction fans and evacuators. 7) Ifthe treater unit mount segmented electrodes, the first page on the LCD display is: Flas feat aS) PS alt oT tl cenenntor IGT 4FERRARINI & BENELLI GORONA TREAUMENT With the sign TOTFIL CISCHARGE flashing. Verify that the value on is ue same that you really use (if necessary, change the value with the tunoas (2 2} and |2"ap and than press button: (0 confirm and enable the discharge. Ifyou don’t confirm, you cannot start the discharge, 8) Press AQ and if the conditions as per points 1), 2), 3), 4), 5), and 6) occur, the red STOP pilot lamp light goes off and the green START light comes on. The alarm signallers are automatically enabled and the generator delivers power whose value can be visualised on the 3 digit display OUTPUT POWER. 9) With the LCD display MENU positioned on the first page: Be TRIE) TIME|N|T rallied 128 10)Press the key |a.z} until you reach the necessary power for treating the film at the desired dynes/em value. ‘As the power increase$ from minimum to maximum the MENU display shows: TRATTRMENTO PIN qu Atminimum: 100% AtMAXIMUM: * 0 spi! 100% (ona TRATTAMENTO Mn) SOOO 11)To reduce power, press key 12)To interrupt discharge press key @ the START light goes out and the STOP light will comes on. connor IGBr 2FERRARINI & BENELLI CORONA TREATMENT 15.2 Description of generator control panel MAIN SWITCH PUSHBUTTON PANEL SOUND SIGNAL MAGNETO- THERMAL ‘SWITCHES AND. FANS 1) GENERATOR MAIN SWITCH QS: station main switch. 2) SWITCHES 1aM1, 1QM2, etc.: generator, fans and motorizations protection magneto- thermal switches. 3) SOUND SIGNAL: activated automatically when the generator goes into alarm, 4) PUSHBUTTON PANEL: contains the generator functioning buttons and pilot lamp lights. (See 15.2.1). cenenntor IGBT AeFERRARINI & BENELLI CORONA TREATMENT 15.2.1 Pushbutton panel 15.2.1.1 Keys 3 1) START DISCHARGE KEY |] press to switch on discharge or refresh the alarm status, 2) STOP DISCHARGE xr @ press to interrupt Corona discharge or to make the alarm refresh, ress to enable/disable sound alarm 3) SOUND ALARM ENABLE/DISABLE KEY signaller (automatically inserted on pressing 4) VALUE MENU. 5) VALUE KEY; press to decrease the parameter’s value highlighted on the LCD MENU. KEY: press to inerease the parameter’s value highlighted on the LCD 6) PAGE [Qa]] KAY: press to pass on to the next page on the LCD MENU (or to the subsequent value if there is more than one on the same page). 7) PAGE efi) KEY; press to pass on to the previous page on the LCD MENU (to the preceding value if there are more than one on the same page). conor IGE ttFERRARINI & BENELLI CORONA TREATMENT 15.2.1.2 Pilot lamp lights 1 TRATTAMENTO: MAH 8 2|> | oooon ose Sno ; 7 3 4 5 1) ALARM light: when lit it signals that one or more protective devices have intervened, causing blocking of discharge delivery: itis activated by: Sensors on the treater or in the generator: a) Opening of the protection hoods. b) Opening of the electrodes pneumatic system. ©) Switching off of the suction fans or insufficient air-flow, 4) Insufficient discharge rolls tuming. Generator internal protection circuit in the case of: ©) Short circuits. £) Over-currents, : 2) Over temperature on the iGBT module heat sink. h) No communications between FB-9701-FRNT and FB-0301-1/02 cards. i) No communications between FB-9701-FRNT and FB-9703B-DRIVER+BST cards. lll the points from a) to g) turn on the correspondent led too (see point 5). The point h) never lights on other led, but the display shows the write ALARM: HO COMMUN. WITH 1/0 GARD flashing. The point i) never lights on other led, but, the display, on page Historian of events (17.9), show in the last event the write DRL) GOMMUNLAL. 2) Three-digit display OUTPUT POWER: Indicates the power effectively delivered by the generator, expressed in kilowatt (Kww) or in Amps (A). 3) START light: when lit it signals that the generator is delivering power. 4) STOP light: tit when the generator is ih stand-by position (ready to recommence with subsequent depression of the START key). cenerston IG BT a3’) 8) 0) FERRARINI & BENELLI CORONA TREATMENT ALARM and SIGNAL lights: a) © SHORT CIRCUIT when lit it signals that the output frequency is going under a threshold; normally it’s caused by: — Short circuit on the treater unit: holes in the discharge rolls covering (for treater with metallic electrodes); holes in the ceramic electrode (for treater with ceramic electrodes); loosing insulations in the insulators; store of condensate on the insulators; [HFT] fault — Short circuit in the generator: iGBT module fault; [R3-C3-C4) filter fault; FB- 9703B-DRIVER+BST card fault or FB-9703-DRIVER or 0302 AL-DRV or 0901-ADM; absence ZEROCROSSING signal — Loss in feeding generator line. b) © OVERLOAD light: when lit it signals the intervention of protection devices due to excessive power absorption by the generator. ¢) ® TEMPERATURE light when lit it signals that the iGBT heat sink has risen above 70°C. 4) © EXHAUST FAILURE light: active only in treatment plant providing for ozone suction control. It collects all the alarms regarding ventilation: presence of ozone evacuator, presence of flow sensors, presence of pressurization system, presence of discharge rolls cooling fan, presence of ozone destruction system (where envisaged). When lit it signals that at least one of the airflow systems is not functioning, ©) © LOSS OF TREATMENT: inadequate treatment. Activates the sound alarm to advise the operator that the machine cannot discharge the set power. This function does not stop the generator. It lights up together with the ALARM LED without bringing the generator to a halt. £) © DOORS OPEN light: when lit it signals that at least one of the doors is open. g) © PNEUMATIC ‘SYSTEM OPEN light: when lit it signals that the electrodes, rollers or structure are open and not in working position. h) ® ZERO SPEED light: when tit it signals that the discharge roller is turning at a speed lower than that envisaged for starting Corona discharge. i) © REMOTE: when lit it signals that the Remote Control is active. COMMUNICATION: when lit it signals that communication between internal generator cards is active. SET POWER led bar: indicates the power percentage requested from 0% (~ discharge off to 100% (= maximum power), MENU LCD display:’ presents the pages and the modifiable values of the functions available for the generator in use (see chapters 17 and 18). GENERATOR IGBr ieCORONA TREATMENT f=3 FERRARINI & BENELLI 16. CONTROL CARD FUNCTIONING PRINCIPLE, Hel 16.1 Card 9701 - FRNT | User interface ¢ard; It hooks up the control buttons and the control microprocessor of the interfacing, | Mounted on the door. J Connection card between power governing card 9703 and user interface card 9701. It collects the input of sensor signals from the treater i It generates outputs for any external signals Manage the watch/calendar system. Store the historical events. Allow the external peripheral unit connection, B] Mounted on the door. 16.3 Card 9703 - DRIVER or 9703B — DRIVER+BST Power circuit control card. Receives signals. = from =the ZEROCROSSING detecting T.A. and power reading, It hooks up the microprocessor that generates the iGBT governing impulses. Frontally mounted on the shelf. Driving card iGBT module. It receives the fault signals from the iGBT module in case of over current and short circuit, 0302‘ALDRV*i8"fidunted on the heat waster beside the iGBT modules in the TLX and TMX models. 0901-ADM is mounted on the base in the M model. cenrnton IGBT byFERRARINI & BENELLI CORONA TREATMENT 17, STANDARD FUNCTIONS 17.1 Power control It allows a feedback loop to strictly maintain the output power constant so as to guarantee a constant treatment level at start-time and all working time. This regulation is fully automati The same function prevents the “generator from exceeding the maximum set for the generator in use. 17.2 Soft Start This permits a gradual starting of Corona discharge so as to avoid “stressing” the generator components with brusque starts at maximum power. This function is fully automat 17.3, Manual power adjustment Tlelalt Hell! et = Pc. mc. Ea If the function Power setting of the Discharge Density (see 18.1), the function R.P.V. ‘Adjustment of Power in function of Speed (see 18.3), the function Skip treatment (see 18.5) 3.2 or the function Wer start (see 18.6) is disabled, with the keys and |2._,a} itis possible to adjust the generator between minimum and maximum delivered power. The value set is indicated on the led bar SET POWER (in %) and on the second row on the LCD display (in W or Amp,), while the effective value delivered is shown on the digital display OUTPUT POWER (in kW or Amp.) E 174 Setting of total width electrodes in discharge position Ha] Fe) | {ESL | ce TT AL (EH 1S bal ENT IH) THIS PAGE IS AVAILABLE ONLY FOR TREATER UNIT EQUIPPED WITH SEGMENTED ELECTRODES. It allows to indicate to the generator the effective length of the electrode that is set in discharge position. The correct setting of this data is important because it allows the generator to change the limits of the power you can supply in relation with this width, c GENERATOR IGBr aidFERRARINI- & BENELLI CORONA TREATMENT This allows to perform two functions in case you use only a short length of the electrode: 1. It will be possible to fall down under the set minimum level for working with the whole electrode in discharge position (MIM): the new minimum level (MIF) will be proportionally lower than MIM. 2. It will be no longer possible to reach the maximum allowed MEH (that is exploitable only with the whole electrode set in working position) so that you will not damage the silicone sleeve or the insulators of the treatment station by trying to discharge too much power along a short electrode: the new maximum (MA+R) will be proportionally lower than MFM In case of segmented electrode this page will automatically appear with the script TOTAL. DISCHARGE flashing whenever you switch the generator on, Check that the total sum of the electrode actually in discharge position on the treatment station corresponds with the measure showed on the display (in contrary ease correct by the key: push for confirmation and in order to start up the machine It_will_not be possible to start the discharge as long ‘as you have not given the confirmation, In case of bilateral treatment station the measure you have to set is given by the sum of the electrode in discharge position of both rolls. ” 18: It is adjustable (by the buttons [q’.'2] and |2"'a}), from a minimum of 5 em up to the maximum for the coupled treatment station with 5 cm step. on, its enough to goon the 2 page ofthe LCD display (by the keys|[V=]] anal =P), The modification of this parameter is inhibited when the discharge corona is on with the Wet start function on (see 18.6). In case it is necessary to change the value of this length when the generator is already switched ei} 17.5 Sound alarm management fil LG] WALI Rh Permits verification of-sound alarm status: * HES: Sound alarm enabled. * HO: Sound alarm disabled. With the button the condition can be modified indeperidently of the page selected on the LCD.MENU. ven if the sound alarm is disabled, the visual alarm and the alarm signals that block the generator remain active. como IGBY oaFERRARINI & BENELLI CORONA TREATMENT 17.6 Discharge rolis speed in, Visualises the current discharge 17.7 Control parameter F Peited F Hist This page shows some working parameters, helpful during diagnostics time: F = Output frequency (in kHz). Fh = FB value useful only for diagnostics. FI = F&B value useful only for diagnostics. FIM = F&B valuc useful only for diagnostics. 17.8 Watch / Calendar The generator is equipped with an everlasting watch and calendar with stopgap battery that guarantees the exact time even when the generator is not fed. ‘The current date / hour will be as follow: ne Even when switching on s the Software version used: ba EL = conmrIGBr 7FERRARINI & BENELLI CORONA TR BATMENT In order to change the date or the hour follow the following instructions: 17.9 Open the door of the generator. Identify the front card FB9701-FRNT mounted on the door itself. The backside of this card is visible. Identify a small switch mounted on it Change the position of this switch, Go back and look the frontal panel. Increase the pages until you find the page: ii sre flashing write. [Al] it will be possible to select the word that has to be By the keys changed (it becomes flashing) oé | vm [mana] wa | mea Day _|Month| Year | Hours |Minute Once you have set the watch, go back (by memorize the new data). Open the door once as Historian of events it will be possible to modify the selected word. the key |) to the page in order to ‘in and set the deviator in the original position. c ALR LAIE IIE HUB) During its functioning, the generator is able to memorize some events and the moment these happens. The memory is kept even when the generator is switched off. GENERATOR IGBY 48FERRARINI & BENELLI CORONA TREATMENT The memorized events are: 1, START DISCH.: Whenever you push the key of discharge start. 2. STOP DIScH Whenever you push the key of discharge stop. 3. SHORT CGIRC.L: Whenever the generator goes in alarm for short circuit, 4, QUERCLRR.ALAR: Whenever the generator goes in alarm for overloading, 5. TEMPERAT.ALAR: Whenever the generator goes in alarm for high T module iGBT. 6. Ti ZONE FLFR Whenever the generator goes in alarm for absence of ozone suction on treater n°. 7, Ti HOODS ALAR Whenever the generator goes in alarm for doors opening on treater n°l. 8, Tl FHELIM.ALAR: Whenever the generator goes in alarm for pneumatic system opening on treater n°1. 9. T1 SPEED ALARM: Whenever the generator goes in alarm for stopped discharge roll on treater n°1. 10, ALITOSTART: Whenever the generator automatically re-starts because of AUTOSTART function active (see 18.2). 11.7% COME ALAR: Whenever the generator goes in alarm for absence of ozone suction on treater n°2. 12, TE HOODS ALAR: Whenever the generator goes in alarm for doors opening on treater n°2, 13.1 FHELIM.FILAR: Whenever the generator goes in alarm for pneumatic system opening on treater n°2. 14,1 SPEED ALARM: Whenever the generator goes in alarm for stopped roll on treater n°2, 15, DRL COMMUPLAL: Whenever the generator goes in alarm for absence of communication between 9701-FRNT and 9703-DRIVER or 9703B-DRIVER+BST (abbreviation in DRY) cards. Alll the alarms here indicated are described at the chapter 15.2.1.2 at the voice 5) ALARM and SIGNAL lights ‘The voices 11, 12, 13, 14 are available ONLY if the generator has to control TWO treaters contemporarily. 50 events recorded by the generator during The page in object allows to visualize the la its functioning, fre 8.1 By the keys f._2] and|z. a} it will be possible to let run all the recorded events. ‘The second line of the page shows the date and the hour when the event happened. GENERATOR IGBY + °FERRARINI & BENELLI CORONA TREATMENT The first couple of numbers at the top on the left shows the position, in the historian, of the recorded event: The position 01 presents the OLDEST recorded event. The position $01 presents the MOST RECENT recorded event. If the historian is not full yet (less than 50 signals), each new signal occupies the position next to the previous event. Ex. If the last event was memorized at the position BE, a new event will occupy the position 25: If the historic is full (it already contains 50 signals), the recording of a new event is made at the position 50, by shifting back of one position ail the events currently recorded end by eliminating the event (the oldest) recorded at position 1d In order to cancel the historian completely, push gontemporarily the keys [p77] and a0 |2/va] and the following inscription will appear Hi) RELPCR IT ELT ORIEIE: lee At this moment every new event will be recorded from position O41, O&, ... and so on until the 50 available positions are filled up; at this point they will start to be deducted as described above. 17.10 Discharge density F fel ea A | ba HIRT HI SIN [S |e Permits enabling the calculation of the surface discharge density (DS). This value represents the discharge density necessary to treat a material at the experimentally measurable dynes value independently of line speed and film width (see paragraph 10.4), It is possible to list the DS values used to obtain the dynes values measured for each material being worked. : In this way, during subsequent work processes the operator will be able to set the generator power in such a way that DS is equal to the listed value for that material, thus ensuring the same treatment value. Possible values: + DISABLE: display of calculation of discharge density DS disabled. © ONLY DISPLAU: display of calculation of discharge density DS enabled. cero IGBT at)FERRARINI & BENELLI CORONA TREATMENT In case of segmented electrode, for the correct calculation it is necessary to set the treatment width, that is the exact total length of the electrode in discharge position. by the visible function at page TOTAL DISCHARGE (sce 17. In case of single bar electrode the total Iength of the discharge is already memorized at the test phase at F&B’s factory. The calculated value will be showed on the first page and expressed in W*min/m*: I EIA Treelt|T Pe Hine lolslel= = N.B.: in case of processing in which the speed changes during the production cycle (for example slowing due to reel changes in automatic), by the qualification of the optional fimetion RP.V. (see 18.3), the value DS will remain constant for all speeds included between the VMAX set in the function R.P.V. and the speed that will give the minimum power of the generator (line B/C). ‘Above the VMAX, DS progressively decreases (because the generator has reached the maximum power that can be supplied) (line C-D). On the contrary, below the speed that allows to supply the minimum power, DS progressively increases (because the generator never goes below the minimum power in order to avoid a “treatment” because of a too thin discharge) (line A-B). 17.11 Minimum STOP Speed aT aya le) SIFIEIE/D) E [SIH|H ira This permits setting the discharge roller speed (expressed in m/min) below which there is automatic stopping of Corona discharge. cermmron IGBY esFERRARINI & BENELLI CORONA TREATMENT 18. OPTIONAL FUNCTIONS I 18.1 Power setting of the Discharge Density If'it is enabled, in the page: It is possible to impose, besides the values DISFBLE and ONLY DISPLAY described at point 17.10, the following values: * CONTROL POMER: enabling this item, in the first page, it will be possible to set up the wished Discharge density (DS). The generator, in relation to the electrode width settled (sce Setting of total width electrodes in discharge position 17.4) and of the line speed pointed out (see Discharge rolls speed 17.6), will calculate the necessary power to obtain this DS. In this way, in case there will be changes of the line speed, the generator will calculate, in automatic, the new power to be supplied in order to keep constant the treatment level. In the case that (for plants with segmented electrodes) the width of the discharge electrode chariges, it will be always the generator that calculates, in automatic, the necessary power for the new sector set in order to maintain the DS uniform. In case that, in relation to the set parameters (Dsi, electrode width, speed of the roll) the calculated power is out of the range of acceptable power for the generator, and so the generator cannot supply the DS demanded, it will be indicated in the first page, by the flashing of the second line, that is the line of the supplied DS (Dse) © CTRL FOL + ALARM: by enabling this voice the working is the same as the above-mentioned working; moreover, when the calculated power level will be out of the range of acceptable power, beside the flashing (in the first page) of the line N. 2, there is also the sound of the sound alarm. In any case the first page it will be as follows: TREAT). | Vsti BUM) PENSE) = (IM) [et 8 [3.7 : and thought the keys [a”.2) and (z\"a} it will be possible to change the value of the Dsi demanded. This method for checking the power, if enabled, has the priority in comparison with the manual control and with the control through the R.P.V, function (see paragraph 18.3). cmon IGBT 52f FERRARINI & BENELLI GORONA TREATMENT 18.2 Autostart - TT [| Jalulrlols|r]elehr salealeaa[sloalalsloa[alealoallea ea This permits setting the type of automatic start and the speed of the discharge roller (expressed in m/min) above which Corona discharge is switched on. For the AUTOSTART type selection page the possible values are: : « GISELE: Autostart disabled. Activation of any one of the alarm sensors (doors, pneumatic system, ozone suction or roller speed) interrupts delivery of Corona discharge. It is ALWAYS necessary to press the START key to reactivate discharge. * SPEED: Autostart enabled only for discharge roller rotation. If alarm conditions permit, (ALARM pilot lamp off and generator on STAND-BY), and the discharge roller tums at a speed greater than the minimum, the Corona discharge is automatically switched on. Fach time the roller drops below the minimum speed, the generator interrupts discharge until the speed returns above the minimum. If discharge is interrupted by any one of the other alarms, even when the alarm condition returns, the generator does not restart by itself but requires pressing the START bution, © SPEED-HOOD-FHELIM: Autostart enabled for discharge roller_rotation, door opening/closing, and pneumatic system opening/closing. ‘Any alarm concerning doors, pneumatic system or roller speed blocks discharge; when the alarm returns to normal the generator restarts discharge automatically, taking it back to the preset value. In this case the pilot lamp of thé alarm that blocked discharge will remain lit in order to permit identification of any defective sensors. Press the START key (also when there is the discharge) to reset the alarms. Setting SPEED or SPEED-HOOD-PHELIM a subsequent page will be enabled where it is possible to set the speed (in m/min) at which to permit automatic start of discharge (which obviously must be a value greater than the one set for the Minimum STOP Speed function (see paragraph 17.11). T RLM) (ORAL SIFIEIEIC] [=| |x io The keys w@ and @ has ALWAYS priority over this function: However you set the AUTOSTART function, the FIRST START must be forced manually by pressing the key Moreover, if you press key (@J}, the generator stop the discharge, even if the function AUTOSTART is enabled. coon IGBY iFERRARINI & BENELLI CORONA TREATMENT 18.3 R.P.V.1 Adjustment of Power in function of Speed —— VOU EIR] AES) | LTH SIPEIE/E) [eR Iu ‘This permits automatic adjustment of power delivered in function of discharge roller speed ‘The progress of power in function of speed is based on a diagram of the following type Hypothesis ‘Minimum power generator can deliver = 1,5 kW Maximum power generator can deliver = 10 kW Max. speed at which max. Power is desired = 200 m/min Deca espe in) Progress is: i * The generator delivery the minimum power if it calculates a value under its set minimum (to avoid a “spotted” treatment) (line A-B). * Direct proportionality between roller speed and power delivered, up to the speed at which maximum power is desired (line B-C). * Above this speed the generator will always deliver maximum power (line C-D). ‘The values available are: * MES: Automatic control of delivered power enabled. ‘© Ho: Automatic control of delivered power disabled. If HES is set, a subsequent two pages are enabled where it is possible to set the speed (in m/min) at which maximum delivered power is desired and the maximum power to reach (useful only with this function). Fe au = Es me | = a ee Se cenrmor IGBT _f= FERRARINI & BENELLI CORONA TREATMENT 18.4 Remote control T Pele Te] [chelate ls This enables the generator to communicate with remote control units such as a PLC or satellite keyboard. The values available are: © HE: Remote control enabled. © Mi: Remote control disabled. 18.4.1 System with analogical and digital signals for PLC See proper manual. 18.4.2 System with satellite keyboard ‘The remote operator interface (FRNT2) is identical to the one of the generator (FRNT). Concerning the visualizations, the remote system is a repetition of the interface at generator board. Moreover it will be able to send commands through buttons identical to the ones present on the generator. 18.4.2.1 Composition of remote system © Selector of lighting remote unit. © Buzzer for acoustic signalling of alarms. © Supplementary frontal card (FRNT2). * Card FB-OTT for the communication in optic fibre. 18.4.2.2 Feeding remote system Two solutions are possible: feeding from outside (V=24Vac) or feeding from the Corona ‘generator through propér line 24Vac. 18.4.2.3 Working ‘Through the deviator on the remote box it is possible to switch on / off the remote unit, The remote system waits datas from the generator. If the remote unit doesn’t receive anything for some time, it signals the absence of communication flashing: ace [eh relia) EC] | SAUL] TIH) |S] |) | Pe] To By setting REMOTE GOMTROL on MES it is possible to enable the remote unit to communicate with the generator. This set condition remains fixed when you switch off of the generator. Only in case the received datas are correct, the remote visualizations (identical to the ones ‘on the generator) are set and the datas of command are sent to the generator. ‘The buttons pressed on the generator ALWAYS have priority with respect to the commands sent by remote control, In case of absence of ‘communication, the generator keeps working as if it were independent. cormorIGBY - =FERRARINI & BENELLI CORONA TRE 18.5. Skip treatment TRIER TIME) |T alt LUAITEIR WAS) [=| |x | ils ‘This permits enabling an external sensor fo carry out the treatment at intervals, This is a useful function if it is desired fo interrupt the discharge at regular intervals in order to obtain strips of untreated material transversal to the winding direction of the film. Since welding is highly penalised by the Corona treatment, these untreated strips are generally used for film welds, When this fmetion is enabled, the Soft Start funetion (see paragraph 17,2) is automatically disabled. ‘The values available are Skip Treatment funetion enabled, «NO: Skip Treatment function disabled. Starting procedure: # Press the | Jf} key to start discharge. * Bring power to the desired value (see paragraph 17.3). * Enable the Skip Treatment function by bringing the corresponding page to HES. At this point the discharge will start to throb according to the masking/ not masking phases of the sensor. * In first page the qualification of this function will be indicated by the indication: z TREAT MEM) T UF IMIS |ele eal [o/s |e ol At this point it is no longer possible to modify delivered-power, + To modify delivered power the Skip Treatment function must be brought to H&, go back to the first page, the power value modified and the function re-enabled in the corresponding page. centro IGBY 7FERRARINI & BENELLI CORONA TREATMIENT 18.6 Wet start In the geographical areas that are particularly humid, and in general when the Corona plant 3 switched off for several hours (for example during the week end), in the temporary time between hot electrode (discharge on) and cold electrode (after some hours the discharge is off) it may happen a store of humidity in the discharge zone (electrodes, rolls and insulators) that, together with the dust attracted in this zone by the suction, creates residuals that deposit on rolls, electrodes and insulators. These humid residuals are conductive and so drastically reduce the insulation of the electrodes as far’ as it will not be possible to switch the Corona discharge on because of short circuits. Up to now, the only solution was to remove these residuals and dry well insulators, rolls and electrodes before switching ori the discharge. This function, that implies the use of specific insulators, on the contrary permits to switch the Corona discharge on even in condition of residual humidity on electrodes, rolls or insulators, keeping the discharge lighted also in presence of short circuits transmitted by the store of conductive residuals on the discharge zone The working is based on a start of ihe discharge from a low value of power with a slow increase in such a way that the progressive heating of the electrodes dries the residuals and reduces the possibility to trigger court circuits. In case of short circuit, the process starts again from the initial value and follows again the slope of gradual increase of power. Pay attention to the fact that the burning of these residuals doesn’t remove them from where they are deposited; an excessive store, of these residuals especially if they are ‘on the covering of the roll and (in an inferior way) on the insulators, may reduce their duration. So, in any case, we suggest to arrange for the cleaning and drying the ischarge zone regularly in order to extend the life of the components. In the page: Hid HI it is possible to cnable this function (only with corona discharge off). The available values are: © DISABLE: Wet Start funetion disabled. «LITO: Wet Start function enabled. ELT | FLAT [ce] fed it = u By enabling the function, next to the Voice ALITG a time of waiting will appear. It represents the period of time in which, lighting and switching off the discharge, the function doesn’t operate because it considers the discharge area still hot and so there should not be short circuits caused by humidity, In case you read the voice HIFIT = HO (this means that the Corona discharge has remained off for mote than the expected time for the cooling of the discharge area) at the following lighting the fimetion will operate automatically. - common IGBr PsFERRARINI & BENELLI CORONA TRE Ifit is enabled, 2 additional pages will appear: ietedift] [T=| [else isle] feel [2] | eeleol | thie! | T=] [sled] [lal] [el el | fsleslels)echa in this page you will be able to set the following parameters (only with corona discharge 1, HIFIT = waiting time between two consecutive lightings during which the function doesn’t operate because it is not necessary (in hours (H) and minutes ('). 2, TIME = duration of the function (in minutes (") and seconds ("); necessary for time bringing the generator from PMIM to FAH 3. PHIM = minimum power: starting value (in W) of power when this function is active. 4, FMAM = maximum power: finished value of the power (in W) when this function active. During the start of the discharge, if this function has to intervene, on the first page this inscription will appear: , TRElalT MiE|T rleleilte [olslel=|elele) | and the user will not be able to regulate manually the power because it is controlled by the function itself with a gradual increase from FIM to FMF, In this phase, if the generator notices a short circuit, it will set again the FMIM and will start again with the calculation of time T from zero, When the generator reaches FMM without short cirenits, it considers the function executed with success and will replace the inscription ET with the condition of manage of the power wished by the user. So only at this point the generator will allow the user to modify the power of discharge. From the moment the discharge is switched off (by pushing STOP or because of the intervention of an alarm) the calculation of waiting time (HFT) will start. If the next lighting happens before the waiting time (HFT) is passed, the function will not operate and the user will be able to impose immediately the wished power. On the contrary, if the next lighting happens after the waiting time (M4FIT) is passed, the function will operate automatically as described above. comrorIGBY .=} FERRARINI & BENELLI CORONA TREATMENT 18.7 Manage of two stations In case of two identical stations simultaneously connected to the same generator; this function allows to impose the station (or the stations) where the generator has to supply the power; all of this without modifying the connections between the stations and the generator. In order to do this the generator has to be equipped with a specific Hardware, lu =z = =| 7 eT | E| ‘According to the setting of your generator, the available values are: © GHLU Th The generator switches the discharge on only on STATION 1. © GHLY TE: The generator switches the discharge on only on STATION 2, « Ti & TE: The generator switches the discharge on simultaneously on STATION 1 and STATION 2. ‘The possibility to change this parameter is available ONLY with discharge off. If there is the possibility to have the discharge on only one station or on all the two simultaneously, when the single station is set, automatically the generator will limit the maximum supplied power at half of the maximum power available. 18.8 Rapid reel change This function, which requires a mechanical and clectronic system, speeds up opening and closure of the treater unit pneumatic system to allow the passage of momentarily thickened film (joints not more than 4 mm), thus reducing high-speed line production waste. For further details see the specific manual enclosed. cenratorn JIGBI ; =FERRARINI & BENELLI CORONA TREATMENT [is.-stations : ] In case of unmounting of electrodes group and/or rolls to make maintenance operations it is possible that the weight of these parts of equipment can require an intervention of more people to move them. Follow the prescriptions of the regulations in force for the correct manual movement of the loads, Notes on the various types of plant in produetion, Generator IGBT 6| FERRARINI & BENELLI CORONA TREATMENT 19.20 INN FLAT * Check that suction is always sufficient to ensure good cooling of the ceramic electrodes. (If necessary, clean often the slots between the electrodes). + The electrodes are ceramic coated: avoid film lashing (joints) or hits to the electrodes that might lead to breakdown. + The system is equipped with an automatic adjustment of the AIR-GAP to the different thickness of the plate: the upper part of the station, when it is closed, rests, through the mobile rolls, to the plate and set correctly the discharge electrodes at 1.3mm. © In order to avoid to damage ceramic electrodes, due to the scant transit slit of the plate to be treated, during reel changes it is necessary to open the pneumatic system to allow the passage of the final (and initial) parts of the plate generally are not perfectly plan corm IGBY ieFERRARINI & BENELLI CORONA TREATMENT 19.20.1 AIR-GAP adjustment The correct value of the AIR-GAP (distance between electrode — plate) is 1.2 - 1.3mm. All Corona treating units are strictly checked during the testing phase. Except for deformations or insetting due to accidental hits or voluntary modifications by unskilled operators, our treating units DO NOT REQUIRE any change of the AIR- GAP setting. Consequently please carry out the operations described below ONLY if it is strictly necessary. 19.20.11 AIR-GAP check 1) Leave only the main switch on [QS]. In this way you can use the open / close buttons to open the electrodes. J 2) Close the treater pushing the a CLOSE button, 3) Unscrew the screws (V1) and open the covers. 4) Loosen the screws (Vs) placed on the sides of the rolls (Rs) and lift them. @ J 5) Check the AIR-GAP through thickness gauge in plastic material that has to be included between 1.2 ~ 1.3mm, The thickness gauge has to be slid between the electrode (EL) and the plate (P). The thickness gauge doesn't have to have too much play ot, at the contrary, gets a struck. 6) If the AIR-GAP is correct place the rolls (Rs) on the rolls (Rd, working on the screws (Vs) placed on the sides of the @ fH , rolls (Rs). es Q) a @ 7) Close the wall and lock the screws (V1). cornror IGE alFERRARINI & BENELLI GORONA TREATMENT 19.20.12 AIR-GAP adjustment 1) Leave only the main switch on [QS]. In this way you can use the open / close buttons to open the electrodes, a 2) Open the treater pushing the OPEN button. 3) Unscrew the screws (V1) and —~ofiel ‘ then open the covers. A A ie ES L.A 4) Check the alignment of the rolls (Ri) with the plate (P). In case Qe they are not aligned, work on the screws (VI) placed on the pores) sides of the rolls (Ri) and re-align. Ras a OOOOO wy screws (Vs) placed on the sides of the rolls (Rs) and lift them. 5) Close the treater pushing the ‘CLOSE button, loosen the a os 6) Loosen the screws (V2), and working on the screws (V3), check the AIR-GAP (distance between the electrodes (EL) and the plate (P) through thickness ‘gauge in plastic material that has to be included between 1.2 and 1.3mm. The thickness gauge has to be slid between the electrode and the plate. The thickness gauge doesn’t have to have too much play or, at the contrary, gets struck Once achieved the correct adjustment, lock the screws (V2). 7) Place the rolls (Rs) on the rolls (Ri), working on the screws (Vs) placed on the sides of the rolls (Rs). 8) Close the covers and screw the screws (V1). comrrIGBr — iyFERRARINI & BENELLI CORONA TREATMENT 19.20.2 Disassemble of the electrodes unit 1) You can leave only the main switch on (@8]. In this way you can use the open / close buttons to open the electrodes 2) Before starting, place a thick cloth between the electrodes and the plate. 3) Close the treater pushing the CLOSE button. 4) With the treater closed, unscrew the serews (V1) and open the door. 5) Unscrew the screw of the feeding cable (V2) and then the two screws (V3) placed on the sides of the electrodes unit (BE). 6) Release the electrodes unit (BE) from the supports (SE) and extract the electrodes unit (BE) making a 90° rotation. The electrodes unit has to pass between the roll (Rs) and the tie rod (T). 7) To reassembly the electrodes unit (BE) repeat backwards from point 6) to 4). cenrmton IGBT — a0.